Adjustable suture-button constructs for ligament reconstruction

ABSTRACT

An adjustable suture-button construct for ligament reconstruction. The construct is a knotless, adjustable, flexible suture loop, a first fixation device (a free or removable slotted button) and optionally a second fixation device (a fixed, non-removable button). Suture ends of the knotless suture loop provide a variable-length graft support that can be adjusted prior to, during, or after deployment of the constructs. The removable, detachable fixation device is provided with attachment feature(s) to permit assembly onto the adjustable loop. The removable, detachable fixation device is attached to the tibia end of the loop construct after the loop construct is passed through the tibial tunnel (i.e., once the loop exits the anterior tibia cortex). If a fixed, non-removable button is employed, the fixed, non-removable button is securely attached (by stitching, for example) to the graft.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of application Ser. No. 14/087,703, filed Nov.22, 2013, now U.S. Pat. No. 9,204,960, which is a divisional ofapplication Ser. No. 13/298,939, filed Nov. 17, 2011, now U.S. Pat. No.8,591,578, which claims the benefit of U.S. Provisional Application No.61/414,715, filed Nov. 17, 2010, the entire disclosures of which areincorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates to the field of surgery and, moreparticularly, to ligament repair/reconstruction, such as, ACL and PCLrepair/reconstruction techniques and associated fixation andreconstruction devices.

BACKGROUND OF THE INVENTION

The posterior cruciate ligament (PCL) is one of four ligaments importantto the stability of the knee joint. The PCL prevents the tibia fromsliding too far backwards. Along with the anterior cruciate ligament(ACL) which keeps the tibia from sliding too far forward, the PCL helpsto maintain the tibia in position below the femur.

Surgical reconstruction of the PCL is usually recommended only for gradeIII PCL tears because of the overall technical difficulty of thesurgery. Surgical PCL reconstruction is difficult in part because of theposition of the PCL in the knee. Trying to place a new PCL graft in thisposition is challenging and, over time, the replacement PCL graft isnotorious for stretching out and becoming less functional.

Adjustable suture-button constructs and associated techniques forfixation of a tendon or ligament, such as an ACL, are disclosed in U.S.Patent Application Publication Nos. 2010/0256677 and 2010/0268273, thedisclosures of both of which are incorporated herein in their entirety.It would be desirable to provide similar adjustable suture-buttonconstructs that can be used for PCL reconstruction, as well as forreconstruction of the ACL or collateral ligaments.

SUMMARY OF THE INVENTION

The present invention provides methods and constructs for ligamentrepair/reconstruction, such as PCL reconstruction and ACLreconstruction. The constructs use a knotless, adjustable, flexiblesuture loop, a first fixation device (a free or removable slottedbutton) and optionally a second fixation device (a fixed, non-removablebutton). Suture ends of the knotless suture loop provide avariable-length graft support that can be adjusted prior to, during, orafter deployment of the constructs. The removable, detachable fixationdevice is provided with attachment feature(s) to permit assembly ontothe adjustable loop. The removable, detachable fixation device isattached to one end of the loop, e.g., the tibia end of the loopconstruct after the loop construct is passed through the tibial tunnel(i.e., once the loop exits the anterior tibia cortex). If a fixed,non-removable button is employed, the fixed, non-removable button issecurely attached (by stitching, for example) to the graft.

The present invention also provides a method of ligament repair by interalia: (i) providing a ligament reconstruction system comprising anadjustable, self-locking, knotless, flexible, loop construct with a freeor removable slotted button and optionally a fixed, non-removablebutton; and (ii) securing a PCL ligament, ACL ligament or other graftwith the reconstruction system.

These and other features and advantages of the present invention willbecome apparent from the following description of the invention that isprovided in connection with the accompanying drawings and illustratedembodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a schematic view of a reconstruction assembly of thepresent invention, including a knotless suture-button construct with afixed, graft button and a removable button (in the pre-assembled form)for ligament reconstruction, and according to a first embodiment of thepresent invention.

FIG. 2A illustrates the fixed, graft button of the knotlesssuture-button construct of FIG. 1.

FIG. 2B is a top view of the intertwined threaded flexible member andfixed graft button.

FIGS. 3, 4A, 4B, 4C and 5 illustrate the steps for forming the knotlesssuture-button construct of FIG. 1.

FIG. 6 illustrates a perspective view of the reconstruction assemblyresulting from the steps illustrated in FIGS. 3-5.

FIG. 7. illustrates a driver instrument for engaging the removable,detachable button.

FIG. 8 is an enlarged view of the instrument head and the removablebutton.

FIG. 9 illustrates loading of the removable, detachable button onto theknotless suture-button construct using the driver instrument.

FIG. 10-16 illustrate an exemplary method of attaching a knotlesssuture-button construct with a fixed, graft button of the presentinvention to a graft to form a PCL graft construct.

FIG. 17 illustrates a PCL graft construct of the present invention.

FIGS. 18-28 illustrate a method of deploying the PCL reconstructionassembly of FIG. 17.

FIG. 29 illustrates another suture-button construct for use with thepresent invention.

FIGS. 30-33 illustrate the assembly of additional ligament-constructembodiments using adjustable knotless loop constructs of the presentinvention.

FIGS. 34-46 illustrate the exemplary steps practiced in deploying theligament-constructs of FIGS. 30-33.

FIGS. 47-52 illustrate another adjustable, knotless suture construct ofthe present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides methods and reconstruction systems(knotless, adjustable loop constructs with a removable, detachablebutton) for ligament repair/reconstruction in a minimally invasiveapproach.

In embodiments of the present invention, methods and reconstructionsystems (knotless, adjustable loop constructs with a removable,detachable button) for PCL/ACL repair/reconstruction in a minimallyinvasive approach

In one embodiment, the reconstruction system comprises a suture-buttonconstruct formed by a first fixation device (for example, a graftbutton) attached to an adjustable, knotless flexible loop; and a free,removable, detachable second fixation device (for example, a slottedbutton). The graft button is preferably a round button (having fourregular holes) with two small “extra” holes to allow stitching to thegraft. The detachable button is slotted to allow assembly onto the loopconstruct. The detachable button is attached to the tibia end of theloop construct after the loop construct is passed through the tibialtunnel (i.e., once the loop exits the anterior tibia cortex). Tractablesuture ends of the knotless suture loop provide a variable-length graftsupport that can be adjusted prior to, during, or after deployment ofthe constructs.

In another embodiment, the reconstruction system comprises anadjustable, knotless flexible loop and only one fixation device, i.e.,only a free, removable, detachable button (without a fixed button). Theremovable, detachable fixation device is provided with attachmentfeature(s) to permit assembly onto the adjustable loop. Tractable sutureends of the knotless suture loop provide a variable-length graft supportthat can be adjusted prior to, during, or after deployment of theconstructs.

In another embodiment, the reconstruction system comprises adjustable,knotless flexible loops and discrete fixation devices, one of which is afree, removable, detachable button (without a fixed button). Theremovable, detachable fixation device is provided with attachmentfeature(s) to permit assembly onto the adjustable loop. Tractable sutureends of the knotless suture loop provide a variable-length graft supportthat can be adjusted prior to, during, or after deployment of theconstructs.

The present invention also provides methods of ligament repair by interalia: (i) providing a ligament reconstruction system comprising anadjustable, self-locking, knotless loop construct with a detachable,free, removable button that is assembled onto the knotless loopconstruct (and optionally with a non-removable, graft button stitched toa graft); and (ii) securing a ligament or graft with the reconstructionsystem.

Referring now to the drawings, where like elements are designated bylike reference numerals, FIGS. 1-28 illustrate reconstruction assembly100 (with one fixed, suturable button and one removable, detachablebutton) and methods of PCL reconstructions (including arthroscopic inlaytechnique) with the assembly 100. The implant/assembly 100(reconstruction system 100) of FIG. 1 includes an adjustable, knotless,flexible loop construct 50 formed from a flexible material 30 withbutton 10 to be attached to the graft (e.g., the graft button), bysewing or other suitable attachment techniques. A second, slotted button20 which is capable of removable attachment to the tibial end of theloop construct after it is passed through the tibia (the detachable,removable button). Alternatively, the slotted button 20 is capable ofremovable attachment to adjustable, knotless, flexible loop construct 50wherever deployed. Buttons 10 and 20 of the construct 100 may be formed,for example, of metal, PEEK or PLLA.

The graft button 10 is about 10 mm round button (having four regularholes) with two small “extra” holes to allow stitching to the graft. Thedetachable button 20 is about 12 mm×8 mm and is slotted to allowassembly onto the loop construct. The slots 22 will allow it to beloaded onto the thinner, proximal loop segment (non-spliced section) butwill not allow passage of the thicker loop segment (spliced) near thetibia to prevent detachment from the implant. As detailed above, thebuttons are provided with openings that allow the passage of theflexible material 30 to pass thereto. The detachable button 20 may beprovided on a driver 60 that holds the button onto a “forked” tip tosimplify loading. Once the detachable button 20 is loaded, the forkedtip can be retracted by sliding a button on the handle, which willrelease the detachable button.

FIGS. 1 and 6 illustrate schematic and perspective views of assembly 100of the present invention, in a pre-assembled form. Assembly 100 includesa knotless suture-button construct 50 formed of a knotless, flexible,adjustable suture member 30 formed from a flexible member 32 and afixed, non-removable fixation device 10 (graft button 10) and aremovable, detachable fixation device 20 (button 20). The flexiblematerial 30 may be a high strength braid construct such as an ultrahighmolecular weight (UHMWPE) braid. The flexible material 30 may beprovided with optional colored strands to assist surgeons indistinguishing between suture lengths with the trace and suture lengthswithout the trace. Assembly 100 may be provided as a kit of components.The knotless suture-button construct has an adjustable loop length andallows adjustment in one direction while preventing or locking theconstruct from loosening in the opposite direction, due to appliedtensile forces.

FIG. 2A shows a top view of the first fixation device 10 used for theknotless suture-button construct 50 shown in FIG. 1. In an exemplaryembodiment only, the first fixation device 10 is a round button providedwith a plurality of circular holes. In an exemplary embodiment only,button 10 is a 10 mm diameter titanium button with 6 round holes, e.g.,holes 1-4 and stitching holes 5 and 6. FIG. 2B illustrates theintertwined flexible member discussed in detail below with the flexiblemember cross-over “X” 35.

FIGS. 3, 4A-4C, 5 and 6 illustrate exemplary steps of forming theknotless suture-button construct 50 (with the following exemplarystarting materials).

Starting Materials:

-   -   A braided high strength (UHMWPE) suture strand 32.    -   A needle with nitinol loop 55.    -   A round titanium button 10 with six holes.

Assembly Instructions for Reconstruction Assembly 100:

Step 1: One tail/end 38 of braid 30 is passed through hole 1, then backdown through hole 2 of the button 10 (FIG. 2) forming a flexible memberstrand section 33 that bridges holes 1 and 2.

Step 2: About 12 inches of the longer strand (second tail) is passedthrough hole 3 adjacent to the first hole of button 10 to create a loop31 (FIG. 3).

Step 3: The tail end 38 of the same strand that passed through hole 3 ispassed under the strand section 33 bridging holes 1 and 2 and thenpassed over the strand section 33 and down through hole 4 of button 10(FIGS. 2 and 4A-4C). This forms an intertwining or interlinking “X” 35of the braid (FIGS. 2 and 4A-4C). The strand looped across holes 1 and 2will be linked with the strand across holes 3 and 4.

Steps 4 and 5: The loop 30 is tightened to create an apex 48 at thecenter. One tail strand 34 is used to create an eyesplice 40 terminatingat the apex 48 of the braid loop 30 (FIG. 5), where FIG. 5 is a partialview of the suture member 32 after it has been threaded through button10. The first splice 40 is created by passing the blunt tip needle 55and a tail end 38 through the center of the braid 30 with the strandbeing carried through in the nitinol loop of the needle 55. Step 5:Splicing is repeated with the remaining tail end (also 38) on theopposing side of the loop to form a second splice 45 of adjustable,knotless loop 30 (FIG. 5). FIG. 6 illustrates the adjustable, knotlessconstruct with the button 10.

As button 10 is attached to flexible material 32 and includes twoadjustable eyesplices 40, 45, pulling on the free braid strands 34, 36respectively constricts the individual eyesplices 40, 45, and in turn,reduces the loop length of loop 30. In order for loop 30 to elongate, aforce needs to be applied interior to one or both of the eyesplices toelongate the individual loops.

The slotted button 20 can be attached to the tibial end of the loop (tothe proximal, thinner non-spliced loop segment) after it is passedthrough the tibia (the detachable, removable button 20). The graftbutton 10 may be an exemplary 10 mm round button (having four regularholes) with two small “extra” holes to allow stitching to the graft. Thedetachable button 20 may be an exemplary 12 mm×8 mm button and isslotted to allow assembly onto the loop construct.

A driver instrument 60 (FIGS. 7-9) easily holds button 20 for loading.Driver 60 includes a “forked” tip 66 at the distal end of shaft 67 withprongs 68 which detachable hold button 20. Once the button 20 is loaded,the forked tip 66 can be retracted by sliding a button 61 on handle 62of the driver 60, which will release the button 20. The button isreleased and pulled distally. The button cannot fall off the loop andthe implant 100 can be tightened. FIG. 9 is a perspective view of thereconstruction assembly 100 of the invention, with fixed, graft button10 and removable, detachable button 20 secured on knotless, adjustable,flexible suture loop (suture member) 50.

FIGS. 10-16 illustrate the exemplary steps followed to attach construct100 to bone block 91 of the PCL graft 90. A method of assembling PCLgraft construct involves inter alia the steps of: (i) providing at leastone flexible, adjustable loop 50 construct (a four-point knotlessfixation device) that is capable of adjusting tension (i.e., is providedwith a loop having an adjustable perimeter and length); (ii) attachingthe button 10 of the loop construct 50 to a bone block 91 of a PCL graft90 by suturing the button 10 to the graft 90 through laterally arrangedsmall holes that go through the bone block 91; (iii) passing theadjustable loop 50 through a tibial tunnel; (iv) assembling a detachablebutton 20 onto the loop of the construct 50 exiting the tibia (onto thethinner, non-spliced loop segment); and (v) subsequently, tightening theloop construct to fix the bone block portion of the PCL graft into theposterior socket.

FIGS. 10-13 illustrate one embodiment of preparing the graft 90. Place acoring reamer 92 next to the bone tendon junction in the desiredlocation of the final graft. Use the reamer 92 to drill a 2.4 mm holethrough the bone plug 91. Replace the drill pin with the collared pin 93from the coring reamer. Ream until the blade reaches the tendon. Removeexcess bone with a sagital saw and rongeur to form bone inlay 94 withpassageway 95, until the graft fits in the appropriate sized hole in thesizing block.

Place a passing suture through button 10 and pass through hole 95 (FIG.14). Pull the button 10 down tightly against the tendinous portion ofthe graft 90. Use the open holes in the button 10 to attach the buttonto the tendon 90. With needle 56 stitch the button 10 with suture 96with whip stitches 97 and 98 (FIGS. 15-16). The attachable button 20 canbe loaded onto the implant, over the anterior tibia and tensioned bypulling on shortening strands.

The adjustable suture-button construct of the present inventionfacilitates tibial fixation of the arthroscopic inlay technique. Thearthroscopic inlay provides the benefits of traditional, open inlay PCLreconstruction with the advantage of being an arthroscopic procedure. Asillustrated in FIGS. 18-20, use a guide and a drill for example, anArthrex RetroConstruction™ Guide and a FlipCutter®) about equal to thesize of the reamer 92 to drill a socket 105 approximately 12 mm deepover the PCL tibial insertion site. Remove the FlipCutter® 102 from thedrill sleeve 104 while holding sleeve in place for suture passing. Passpassing suture 106 (for example, a #2 Fiberstick™) through the drillsleeve and into the joint for retrieval through the anteromedial portal.

As illustrated in FIGS. 21-24, a wire (passing suture) is retrieved fromthe joint through a peripatellar arthroscopy portal, and then utilizedto introduce the graft/implant 100 into the knee. An arthroscopicgrasper to hold the graft 90 at the tendon bone junction inferiorly andpush the graft posterior until it reaches the tibial socket. Hold lighttension on the implant (not tensioning strands) to guide the graft 90into position. When the bone block 94 of the graft 90 has reached thetibial socket, as seen arthroscopically and fluoroscopically, pulldistally to seat graft 90. Once the loop construct exits the anteriortibial cortex, button 20 with attachment features (such as slots, forexample) is assembled by the surgeon onto the loop and sliding thebutton 20 distally to the end of the implant. (FIGS. 25 and 26). Tensionstrands 34, 36 of the implant/construct symmetrically and remove anyslack buildup created by one strand by pulling on the other, then pullto cinch up the loop construct and fix the bone block portion of thegraft into the posterior socket. (FIGS. 27-28). The suture is thicker inthe end of the implant, ensuring that the button 20 cannot becomedisassembled from the suture. Once the graft 90 is seated, thetensioning strands may be cut. A knot may be tied before cuttingsutures, to protect the implant during cutting and to act as backupfixation. Proceed with femoral graft passing and fixation.

FIGS. 29-46 illustrate other exemplary fixation assemblies of thepresent invention and associated methods of ligament reconstructions,e.g., for ACL repair. In one embodiment two reconstruction assemblies100 are provided with only removable, detachable buttons 20. In anotherembodiment, reconstruction assembly 100 with a removable button and asecond reconstruction assembly 200 with a fixed oblong button are usedwith graft 190.

FIG. 29 illustrates the reconstruction assembly 200 with fixed button230 and the adjustable, knotless, flexible suture construct 250, similarto construct 50, with splices 240, 245. As with reconstruction assembly100, reconstruction assembly 200 includes the adjustable knotless sutureconstruct of the present invention formed from an open ended, flexiblemember, for example, a braided suture, and is formed in a similarmanner. A first suture tail shortening strand (a free suture end) of theflexible member is spliced through a first segment of the suture on oneside of a mid-section of the flexible member. A first adjustable loop“1” is formed. A second suture tail, shortening strand (the other freesuture end) is first passed through the loop 1 and then spliced througha second segment of the suture on another side of the mid-section toform the adjustable suture construct, illustrated above. The first andsecond segments are off-set and separate from one another. Pulling onthe free ends of the suture (i.e., the shortening strands) adjusts thelength of the graft support.

Suture-button constructs 50, each without a button, are loaded onto thegraft 190. (FIG. 30). Alternatively, suture-button construct 50 with adetachable button and any suitable adjustable suture-button construct,such as the ACL suture-button construct 200 with a fixed button areloaded on respective sides of graft 190, as illustrated in FIG. 31. Onceloaded, the graft 190 is folded into a loop and sutured to create agraft construct 190 (“GraftLink®”), FIGS. 32 and 33.

Femoral and tibial sockets are prepared in the knee, the passing suturesplaced, and graft 190 is taken off preparation station, FIGS. 34 and 35.The femoral adjustable suture-button construct 200 (or 100) is passedand the shortening strands are pulled to advance graft to femur (FIGS.36-37). In the case of two adjustable suture-button constructs 100, oneis similarly passed and pulled through the femoral tunnel.

As illustrated in FIGS. 38-42, the tibial passing suture is tied toadjustable suture-button construct 100 which includes a removable buttonto be subsequently assembled and passed through the tibia. The tibialconstruct 100 is passed through the tibia completely, and button 20loaded by sliding the proximal, thinner part of loop 50 through theslots 22 of button 20 (FIGS. 43 and 44).

FIGS. 45-46): The button 20 is pulled down to the end of the loop 50,near the tensioning sutures 34 and 36. The tensioning sutures are thenpulled to shorten the implant which brings the button to bone andtensions the graft. After appropriate graft tension is reached suturesmay be cut and surgery is complete. A knot (for example, a square knot)may be tied over the button 20 to protect the splice from being damagedand as backup fixation to the self locking suture-button construct.

FIGS. 47-52 illustrate another suture-button construct 300 of thepresent invention including one adjustable and one fixed loop. Thesuture-button construct 300 may be used in conjunction with adetachable, removable button (such as button 20 described above) for thePCL repair detailed above, or for any other fixation of tissue insurgical repairs.

FIG. 47 shows a strand of flexible material 220 (for example, an UHMWPEbraid 220) with a fixed eyesplice 222 at one end (fixed bystitching/interweaving individual strands, as known in the art) to bepassed through button 260. FIGS. 48-52 illustrate sequential exemplarysteps of a method of forming/assembling construct 300 (FIG. 51) of thepresent invention. The construct includes one adjustable and one fixedloop, with an adjustable splice 240 (FIG. 50). One strand controls thelength of the loop, eliminating the need to construct multiple loopsevenly. Stitching is one option for the fixed eyesplice but may includeother methods of locking/creating the fixed splice. For example, onesuch alternative is tying knots 401, 402 at either end of an adjustablesplice (as shown in FIG. 52) to form construct 400. The knots 401, 402are too bulky to pass through the splice tunnel and prevent adjustmentof the splice loop. This results in a strong fixed loop withoutstitching.

While the present invention is described herein with reference toillustrative embodiments for particular applications, it should beunderstood that the invention is not limited thereto. Those havingordinary skill in the art and access to the teachings provided hereinwill recognize additional modifications, applications, embodiments andsubstitution of equivalents all fall within the scope of the invention.Accordingly, the invention is not to be considered as limited by theforegoing description.

What is claimed as new and desired to be protected by Letters Patent ofthe United States is:
 1. A ligament construct for fixation within a bonetunnel, comprising: a first button and a second button, wherein thefirst button has a configuration different from a configuration of thesecond button, wherein one of the first and second buttons has laterallyarranged end slots to allow attachment to and detachment from a flexiblematerial, wherein each end slot forms part of a T-shaped opening in oneof the first and second buttons; a continuous loop of flexible material,wherein the loop has an adjustable length to allow positioning of aligament within the bone tunnel, and wherein the loop is provided withtwo discrete splices that allow adjustment in one direction whilelocking the ligament construct in the opposite direction; and theligament is a PCL graft secured to one of the first button and thesecond button by suture for positioning.
 2. The construct of claim 1,wherein the loop has a length which is about equal to a length of thebone tunnel.
 3. The construct of claim 1, wherein the continuous loop offlexible material is formed of a high strength suture.
 4. The constructof claim 1, wherein the continuous loop of flexible material comprises aself-locking loop of flexible material.
 5. The construct of claim 1,wherein the continuous loop of flexible material comprises a knotlessloop of flexible material.
 6. The construct of claim 1, wherein thefirst and second buttons comprise a metal, PEEK or PLLA.
 7. Theconstruct of claim 1, wherein the slots are located within an oblongshaped button.
 8. The construct of claim 1, wherein the first button isa round button secured to the PCL graft and the second button includesthe laterally arranged end slots for removable attachment of the secondbutton to the continuous loop of flexible material.
 9. The construct ofclaim 8, wherein the round button is stitched to the PCL graft with thesuture.
 10. The construct of claim 1, wherein the laterally arranged endslots include a first slot formed in a first end of the one of the firstbutton and the second button and a second slot formed in a second end ofthe one of the first button and the second button.
 11. The construct ofclaim 10, wherein the first slot intersects a first opening formed inthe one of the first button and the second button and the second slotintersects a second opening formed in the one of the first button andthe second button.
 12. A ligament construct for fixation within a bonetunnel, comprising: a first button and a second button, wherein thefirst button has a configuration different from a configuration of thesecond button, wherein one of the first and second buttons has laterallyarranged end slots to allow attachment to and detachment from a flexiblematerial; a continuous loop of flexible material, wherein the loop hasan adjustable length to allow positioning of a ligament within the bonetunnel, and wherein the loop is provided with two discrete splices thatallow adjustment in one direction while locking the ligament constructin the opposite direction; the ligament is a PCL graft secured to one ofthe first button and the second button by suture for positioning; andwherein the PCL graft includes a bone block.
 13. The construct of claim12, wherein one of the first button and the second button is attached tothe bone block.